Pack to pouch systems

Abstract

A method includes separating a portion of a flattened tube of stock packing material to a custom length to form a pouch pre-form and closing a first end of the pouch pre-form leaving a second end of the pouch pre-form open. The method can include placing product into the pouch pre-form and closing the one open end of the pouch pre-form to form a closed pouch containing the product.

What is claimed is: 
     
       1. A system comprising
 a conveyor; 
 a separator; 
 a controller operatively connected to the conveyor and to the separator to control the conveyor to drive a length of a flattened tube of stock packaging material through the separator, and to control the separator to separate the length of the tube from the tube to form a pouch pre-form; 
 a first closer assembly operatively connected to the separator to receive the pouch pre-form and close one end of the pouch pre-form, wherein the first closer assembly comprises:
 a top vacuum cup above a slide that extends through the first closer assembly, 
 a bottom vacuum cup below the slide, wherein the top and bottom vacuum cups are configured to secure and open the pouch pre-form from opposite sides of the pouch pre-form, and 
 an adhesive applicator mounted for lateral movement relative to the slide that is configured to apply adhesive to the one end of the open pouch pre-form prior to pressing with a pressure plate to close the one end comprising a lower end of the pouch pre-form with respect to the direction of gravity; 
 
 a filling station operatively connected to the first closer assembly to receive the pouch pre-form with the one end closed from the first closer assembly; and 
 a second closer assembly operatively connected to the filling station to receive pouch pre-form with product therein from the filling station. 
 
     
     
       2. The system as recited in  claim 1 , further comprising a set of metal fingers positioned above the pressure plate and adhesive applicator and in opposition to the slide, wherein the fingers are configured to guide the pouch pre-form into the first closer assembly and assist in forcing the pouch pre-form flat against the slide to resist upward memory in the pouch pre-form. 
     
     
       3. The system as recited in  claim 2 , further comprising a plurality of photosensors positioned to detect whether a top layer of the pouch pre-form is in position to allow for insertion of the adhesive applicator into one end of the open pre-form. 
     
     
       4. The system as recited in  claim 3 , wherein the plurality of photosensors includes:
 a first photosensor positioned to detect that the pouch pre-form has dropped from the conveyor and separator; 
 a second photosensor positioned to detect whether a bottom layer of the pouch pre-form is in position to allow for insertion of the adhesive applicator; and 
 third and fourth photosensors positioned to detect whether the top layer of the pouch pre-form is in position to allow for insertion of the adhesive applicator. 
 
     
     
       5. The system as recited in  claim 1 , wherein the filling station includes opposed top and bottom vacuum cups configured to secure and pull open the pouch pre-form for filling by a user. 
     
     
       6. The system as recited in  claim 5 , further comprising a photosensor positioned to register presence of the pouch pre-form for pulling open by the top and bottom vacuum cups of the filling station. 
     
     
       7. The system as recited in  claim 5 , further comprising a clip positioned to rotate into position to hold a lower portion of an opening of the pouch pre-form for an operator to fill the pouch pre-form with product. 
     
     
       8. The system as recited in  claim 5 , further comprising:
 a flip up pan configured to actuate to catch the pouch pre-form after it has been loaded by the user; 
 a main actuator configured to perform a cross transfer of the pouch pre-form by actuating fingers to push a loaded pouch pre-form away from the filling station; and 
 a second actuator attached to the main actuator configured to retract the fingers as a new pouch pre-form is flipped into position, wherein the flip pan is configured to drop downward to enable the new pouch pre-form to flip into position at the filling station. 
 
     
     
       9. The system as recited in  claim 8 , further comprising:
 a pivot and lift, wherein after the loaded pouch pre-form has been cross transferred by the fingers, the pivot is configured to pivot the loaded pouch pre-form forward, and wherein the lift is configured to lift the loaded pouch pre-form to drop onto a final ramp for the second closer assembly. 
 
     
     
       10. The system as recited in  claim 9 , further comprising a drop point actuator configured to drop the loaded pouch pre-form onto the final ramp by actuating a pair of drop pans. 
     
     
       11. The system as recited in  claim 10 , further comprising a motor actuator configured to adjust positioning of the loaded pouch pre-form on the final ramp. 
     
     
       12. The system as recited in  claim 11 , further comprising a first photo sensor that is positioned to detect a leading edge of the loaded pouch pre-form to detect if the loaded pouch pre-form is in correct position while transferring to the second closer assembly. 
     
     
       13. The system as recited in  claim 12 , further comprising a second photo sensor positioned to detect the leading edge of the loaded pouch pre-form at a final position of transfer to the second closer assembly. 
     
     
       14. The system as recited in  claim 1 , wherein the second closer assembly includes a second glue station for closing a final opening of the pouch pre-form. 
     
     
       15. The system as recited in  claim 14 , wherein the second closer assembly includes a first pressure bar and a second pressure bar, each with a respective actuator, wherein the actuator of the first pressure bar is configured to move the first pressure bar downward from above the pouch pre-form, and wherein the actuator of the second pressure bar is configured to move the second pressure bar upward from below the pouch pre-form to help ensure a seal. 
     
     
       16. The system as recited in  claim 15 , wherein the second closer assembly includes opposed top and bottom vacuum cups configured to secure and open the pouch pre-form to allow for insertion of a second adhesive applicator. 
     
     
       17. The system as recited in  claim 16 , wherein the bottom vacuum cup is mechanically coupled with the bottom pressure bar to inhibit movement of the pouch pre-form when the pressure bars actuate to seal the pouch pre-form as a pouch. 
     
     
       18. The system as recited in  claim 16 , wherein the second closer assembly includes an upper photosensor positioned to detect whether a top layer of the pouch pre-form is in position to allow for insertion of the second adhesive applicator. 
     
     
       19. The system as recited in  claim 18 , further comprising a bottom photosensor positioned for detecting whether a bottom layer of the pouch pre-form is in position to allow for insertion of the second adhesive applicator. 
     
     
       20. The system as recited in  claim 1 , wherein the pouch-preform is a custom-sized pre-form to fit the product.